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Manufacturing plants manage constant vehicle movement for raw materials and dispatch. Stackfusion’s EDM automates gates, material flow, and ERP integration.
OPERATIONAL CHALLENGES
Manual gate registers, paper-based verification, and disconnected ERP processes slow industrial operations, increase errors, and delay vehicle entry, material inward, and dispatch across manufacturing facilities.
Operational Impact of Industrial Gate Automation
By digitizing gate operations, EDM cuts vehicle dwell time, enforces traceability, and removes paper-based steps across industrial entry and dispatch.
Gate Processing Time
80–85%
Reduction
Audit Trail & Reconciliation
100%
Accuracy
Paperless Operations
100%
Digital
Vehicle Turnaround Time
>50%
Reduction
Vehicle Identification Accuracy
99%
Automation
Did you know manual gate operations can slow industrial entry and dispatch?
Digital Systems Driving Plant Operations
Automated Parking Payments
Stackfusion’s Entry & Dispatch Management (EDM) solution digitizes and automates vehicle entry, driver verification, material inward and outward movement across industrial plants. With seamless ERP integration, it enables faster gate operations, full traceability, paperless workflows, and reduced manpower dependency.
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Automated Vehicle Entry
Suppliers or transporters digitally pre-register vehicles and drivers before a trip. Documents including registration validity, fitness, insurance, PUC, Aadhaar, and driving license are verified in real time. Approved vehicles are auto-identified at the gate using AI recognition and FASTag for automated access.
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Material Inward Automation
On vehicle entry, EDM initiates ERP workflows using purchase orders, supplier invoices, and e-way bills. Automated weighbridge integration captures net weight, while cameras record vehicle images, reducing entry time from minutes to seconds and accelerating inward material processing.
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Dispatch & Outward Automation
Dispatch records are created digitally using invoice or ERP references with automatic fetching of delivery challan and e-way bill details. Weighbridge data and vehicle images are captured, and a digital gate pass is auto-issued for controlled material outward movement.
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Returnables & Special Handling
EDM manages returnable materials such as machinery sent for repair, construction equipment, tools, and day-pass entries. Returnables are digitally tracked across inward and outward movement to ensure accurate reconciliation and traceability back into the plant.
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Centralized Visibility Dashboard
The EDM dashboard provides real-time entry and exit logs with vehicle images, ERP references, dispatch status, supplier and transporter history, complete audit trails, and analytics to identify bottlenecks, delays, and operational inefficiencies.
Workforce Safety Monitoring
Safedge provides continuous, real-time workforce safety monitoring by analyzing live camera feeds using computer vision and edge AI. It detects PPE non-compliance, unsafe behavior, and hazardous incidents instantly, enabling faster response, improved compliance, and consistent safety enforcement across industrial environments.
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Real-Time Safety Monitoring
Safedge runs AI models on an on-premise industrial GPU unit to continuously monitor live camera feeds across the site. Safety violations are detected in real time and alerts with visual evidence are triggered via dashboards, mobile notifications, WhatsApp, or optional audio-visual alarms.
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PPE & Compliance Detection
The system detects PPE non-compliance such as missing helmets, safety vests, shoes, harnesses, masks, jumpsuits, eyewear, and gloves. Violations are identified instantly using computer vision without disrupting existing camera infrastructure or site operations.
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Unsafe Behavior & Conditions
Safedge identifies unsafe human movement, restricted zone breaches, height violations, maintenance non-compliance, and people count mismatches in real time. These insights help prevent incidents before they escalate into safety or operational risks.
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Incident & Accident Detection
The AI models detect critical incidents such as fire, smoke, oil leaks, spills, falls, and forklift movements. Real-time alerts allow safety teams to respond immediately, minimizing damage, downtime, and workforce exposure to hazards.
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Customizable & Trainable AI
Safedge continuously learns new scenarios and variations from live environments. The AI models can be customized to support site-specific safety rules, perimeter monitoring, intrusion detection, and additional compliance requirements.
AI Ladle Monitoring Systems
Alloyedge is a vision-based ladle monitoring solution that automatically detects, identifies, and tracks ladles in real time across metals and alloys plants. It reads embossed ladle numbers and monitors movement, rotation, and utilization without manual intervention.
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Industrial-Grade Vision System
Alloyedge uses ruggedized IP cameras with IR illumination to capture live feeds from safe distances in high-temperature and dust-prone environments. Cameras support 24×7 operation, variable lighting, and optional self-cleaning enclosures for reliability.
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Ladle Detection & Identification
The AI model detects moving ladles in real time and accurately reads embossed ladle numbers, even when surfaces are worn or color shifts from dusty grey to molten orange under extreme heat and dust conditions.
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Real-Time Ladle Tracking
Alloyedge tracks ladle movement and rotation across production stages, automatically counting cycles and eliminating manual monitoring. This provides continuous visibility into ladle usage and process flow within the plant.
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Analytics & Production Insights
The solution delivers analytics for ladle utilization, rotation frequency, and lifecycle insights. It also helps estimate hourly production status, enabling better production planning and optimization based on demand or shortfall.
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Edge AI Processing
Alloyedge runs on Stackfusion’s on-premise industrial GPU edge unit designed to operate at temperatures up to 70°C. The unit processes AI inference locally for low latency, reliability, and secure plant operations.
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Enterprise System Integration
The solution integrates seamlessly with ERP and enterprise applications such as SAP, Oracle, Microsoft, and custom systems, enabling real-time data exchange, production traceability, and synchronized plant operations.
